Apparatus and methods for sealing a medicament within a medical delivery device

ABSTRACT

Apparatus and methods for lyophilizing and sealing a medicament within a medical delivery device having an opening. The apparatus may include a stopper for sealing the opening. The stopper may have one or more elongated members extending from a base, in a direction that is parallel to a central axis of the base. One or more of the members may be set radially away from the axis and define a coaxial central well. The member or members may define a void. The elongated member or members may engage a device inner wall and support the base away from the opening. The void may provide gas exchange between a device interior and a device exterior. The gas may be a lyophilization byproduct that escapes from the device interior between the inner wall, the base and the member or members. The stopper may be advanced into the device to seal the opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/032,752, filed on Aug. 4, 2014, which is hereby incorporated byreference herein in its entirety.

BACKGROUND OF THE INVENTION

A medicament may be delivered into a patient by syringe.

The medicament may be loaded into the syringe at the time of delivery tothe patient. The medicament may be “pre-filled” into the syringe priorto packaging the syringe for use by a practitioner.

The medicament may be loaded into the syringe in an injectable form.

The medicament may be loaded into the syringe in a form or compositionthat requires conversion prior to injection. For example, a medicamentthat is loaded in a solid, crystalline, gelatinous, paste, slurry,hydrogel or liquid form may require mixing with another substance thatis in solid, crystalline, gelatinous, paste, slurry, hydrogel or liquidform.

The syringe may be pre-filled with the medicament during manufacture.Pre-filled syringes are advantageous with respect to safety, accuratedosing and simplicity of use.

Some medicaments exhibit low stability in liquid form. Desiccating thesemedicaments, as by lyophilization, yields a dry form with higherstability. Syringes manufactured containing such dry medicament and inwhich the liquid injectable form can be timely reconstituted fordelivery, combine the advantages of pre-filled syringes with enhancedshelf-life.

To obtain the dry form of medicament in situ within the syringe orwithin a syringe part (such as a tube), a medicament-containing interiorof the syringe or of the syringe part is exposed to a desiccationprocess. Typically, the desiccation process proceeds within a setting(for example, a closed chamber) in which temperature and pressure arecarefully regulated. Manufacturing syringes pre-filled with desiccatedmedicament is complicated by re-exposure of the medicament to airbornehumidity following the desiccation process and prior to the interiorbeing sealed off from surroundings outside the regulated setting.

It would be desirable, therefore, to provide apparatus and methods forreducing the exposure to humidity of medicament desiccated within asyringe or within a syringe part.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 2 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 3 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 4 a is another perspective view of the apparatus shown in FIG. 3 ;

FIG. 4 b is another perspective view of the apparatus shown in FIG. 4 a;

FIG. 5 is a partial cross-sectional view of the apparatus shown in FIG.3 , the view taken along lines 5-5 (shown in FIG. 4 a );

FIG. 6 a is a partial cross-sectional view of the apparatus shown inFIG. 3 , the view taken along lines 6-6 (shown in FIG. 4 a );

FIG. 6 b is another partial cross-sectional view of the apparatus shownin FIG. 3 , the view taken along lines 6-6 (shown in FIG. 4 a );

FIG. 7 is an end-view of the apparatus shown in FIG. 3 , the view takenalong lines 7-7 (shown in FIG. 4 a );

FIG. 8 is another perspective view of the apparatus shown in FIG. 3 ;

FIG. 9 is a partial cross-sectional view of the apparatus shown in FIG.3 , the view taken along lines 9-9 (shown in FIG. 8 );

FIG. 10 a is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 10 b is another perspective view of apparatus in accordance withthe principles of the invention;

FIG. 11 is a partial cross-sectional view of the apparatus shown in FIG.10 a;

FIG. 12 is a partial cross-sectional view of the apparatus shown in FIG.10 a , the view taken along lines 12-12 (shown in FIG. 11 );

FIG. 13 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 14 a is another perspective view of the apparatus shown in FIG. 13;

FIG. 14 b is another perspective view of the apparatus shown in FIG. 14a;

FIG. 15 a is a cross-sectional view of the apparatus shown in FIG. 13 ,the view taken along lines 15-15 (shown in FIG. 14 a );

FIG. 15 b is another cross-sectional view of the apparatus shown in FIG.13 , the view taken along lines 15-15 (shown in FIG. 14 a );

FIG. 16 is another perspective view of the apparatus shown in FIG. 13 ;

FIG. 17 is a cross-sectional view of the apparatus shown in FIG. 13 ,the view taken along lines 17-17 (shown in FIG. 16 );

FIG. 18 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 19 a is another perspective view of the apparatus shown in FIG. 18;

FIG. 19 b is another perspective view of the apparatus shown in FIG. 18;

FIG. 20 a is a cross-sectional view of the apparatus shown in FIG. 18 ,the view taken along lines 20-20 (shown in FIG. 19 a );

FIG. 20 b is another cross-sectional view of the apparatus shown in FIG.18 , the view taken along lines 20-20 (shown in FIG. 19 a );

FIG. 21 is another perspective view of the apparatus shown in FIG. 18 ;

FIG. 22 is a cross-sectional view of the apparatus shown in FIG. 18 ,the view taken along lines 22-22 (shown in FIG. 21 );

FIG. 23 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 24 a is another perspective view of the apparatus shown in FIG. 23;

FIG. 24 b is another perspective view of the apparatus shown in FIG. 23;

FIG. 25 is a partial cross-sectional view of the apparatus shown in FIG.23 , the view taken along lines 25-25 (shown in FIG. 24 a );

FIG. 26 a is a partial cross-sectional view of the apparatus shown inFIG. 23 , the view taken along lines 26-26 (shown in FIG. 24 a );

FIG. 26 b is another partial cross-sectional view of the apparatus shownin FIG. 23 , the view taken along lines 26-26 (shown in FIG. 24 a );

FIG. 27 is another partial cross-sectional view of the apparatus shownin FIG. 23 , the view taken along lines 26-26 (shown in FIG. 24 a );

FIG. 28 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 29 is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 30 a is a perspective view of apparatus in accordance with theprinciples of the invention;

FIG. 30 b is a another perspective view of the apparatus shown FIG. 30 a; and

FIG. 31 is a perspective view of apparatus in accordance with theprinciples of the invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

Apparatus and methods for lyophilizing and sealing a medicament within amedical delivery device are provided. The apparatus may be used toperform one or more steps of the methods. The apparatus and methods mayprovide for reconstitution and delivery of a liquid injectable form ofthe medicament.

The apparatus may include, and the methods may involve, a stopper for amedicament delivery device. The delivery device may be cylindrical. Thestopper may include a base for sealing an opening of the device. Thebase may include a central axis. The stopper may include a singleelongated member. The stopper may include two or more elongated members.One or more of the elongated members may have a length. The length maybe the same or different from lengths of other elongated members. Theone or more elongated members may extend away from the base in adirection that is parallel to the axis. The member or members may be setradially away from the axis. The member or members may define: (1) aportion of a central well coaxial with the axis; and (2), extending in acircumferential direction between adjacent portions of a member orbetween adjacent members, a void. The void may be one of a plurality ofvoids. Each void of the plurality of voids may be similar.

The void may have a circumferential span. The span may be a portion of acircumference of the stopper. The circumference of the stopper may be acircumference of the base. A void, or a plurality of voids in aggregate,may span a portion of the circumference. The void portion may bereferred to as a void-fraction circumference.

The stopper may have a first operational configuration. The stopper mayhave a second operational configuration.

In the first operational configuration, the elongated member or membersmay engage an inner wall of the device to support the base away from theopening such that the void provides exchange of gas between an interiorand an exterior of the device.

In the second operational configuration, the base may engage the innerwall to seal the opening.

In the first operational configuration, the gas may be a lyophilizationbyproduct.

In the second operational configuration, the stopper may seal alyophilized product within the device. The product may be disposedbetween the stopper and a plunger that is sealingly engaged with theinner wall of the device.

An operator may move the stopper from the first operationalconfiguration to the second operational configuration by advancing thestopper relative to the opening. The operator may be human. The operatormay be mechanical. The operator may be robotic. The operator may be anyother suitable operator.

The base may adjoin a flange orthogonal to the axis. The base mayinclude the flange. The flange may be configured to abut, in the secondoperational configuration, a terminal surface of the device. Theterminal surface may surround the opening.

The stopper may include a resilient material. The stopper may include alubricious coating. The lubricious coating may coat the resilientmaterial. The lubricious coating may laminate the resilient material.The lubricious coating may be bonded to the resilient material. Theresilient material may bear the lubricious coating.

The stopper may be manufactured by molding the resilient material andthe lubricious coating in conjunction with each other. The molding maybe accomplished through an overmolding process. The molding may beaccomplished through a coinjection process.

The resilient material may include include rubber. The rubber mayinclude chlorobutyl rubber. The rubber may include bromobutyl rubber.The rubber may include chromobutyl rubber. The resilient material mayinclude silcone. The silicone may be molded as a liquid silicone rubber(LSR). The resilient material may include a thermoplastic elastomer. Theresilient material may include a polymeric substance.

The lubricious coating may include polytetrafluoroethylene (PTFE). Thelubricious coating may include ethylene tetrafluoroethylene (ETFE). Thelubricious coating may include a material selected to reduce interactionof the coated surfaces with the medicament. The lubricious coating mayconfer chemical resistance and/or chemical inertness to coated surfaces.The lubricious coating may facilitate movement of the stopper into thedelivery device. The lubricious coating may facilitate movement of thestopper within the delivery device. The lubricious coating mayfacilitate sealing engagement and/or sliding engagement of the stopperwith the inner wall.

The base may include a region that is configured to be penetrated by aneedle. The region may be self-sealing around an outer wall of theneedle.

The central well may taper toward the base. The central well may tapercontinuously toward the base.

The base may include a peripheral ridge. The ridge may be configured tosealingly engage the inner wall of the device.

The device may include a tube. The tube may include glass. The tube mayinclude rigid plastic. The tube may include any other suitable material.

The opening of the device may be an opening of the tube. The terminalsurface of the device may be a terminal surface of the tube surroundingthe opening of the tube. The inner wall of the device may be an innerwall of the tube. The interior of the device may be an interior of thetube surrounded by the inner wall of the tube. The exterior of thedevice may be an exterior of the tube.

The tube may be a part of a syringe. The tube may be part of apre-filled syringe. The pre-filled syringe may be all or part of thedevice. The tube may be all or part of the device.

The tube may not be joined with other parts of the pre-filled syringewhile the stopper is in the first operational configuration. The tubemay be joined with other parts of the pre-filled syringe while thestopper is in the first operational configuration. The tube may bejoined with other parts of the pre-filled syringe only when the stopperis in the second operational configuration.

In the first operational configuration, the lyophilization byproduct gasmay be transferred from the interior of the device to the exterior ofthe device. The lyophilization byproduct may be exchanged for ambientair, initially exterior to the device (for example, air within alyophilization chamber into which the device was placed), which may betransferred from the exterior of the device to the interior of thedevice.

In the second operational configuration, the stopper may be advancedinto the device to sealingly engage the inner wall of the device and/orto abut the terminal surface of the device. The stopper sealinglyengaging the inner wall of the device and/or abutting the terminalsurface of the device may seal the lyophilized product within the devicebetween the stopper and the plunger. The device may be joined with otherparts of the pre-filled syringe while the stopper is in the secondoperational configuration.

The methods may include sealingly engaging the inner wall of the devicewith the plunger. A plunger face closest to the opening of the devicemay be offset from the opening. The methods may include orienting thedevice with the opening at least partly upright above the engagedplunger. The methods may include placing the medicament into the device.The methods may include placing the medicament into the device such thatthe medicament occupies at least part of the interior volume of thedevice above the plunger, below the opening and bound by the inner wall.

The methods may include engaging the inner wall of the device with aresilient elongated member fixed to a sealing base of the stopper orwith a plurality of resilient elongated members fixed to the sealingbase.

The methods may include advancing the member or members into the deviceuntil the base is set apart from the inner wall by a predeterminedoffset. The offset may be referred to as “S.” The offset may scale inproportion to the void-fraction circumference. For example, the offsetmay range from about 1-5%, 6-10%, 11-15%, 16-20%, 21-25%, 26-30%,31-35%, 36-40%, 41-45%, 46-50%, 51-55%, 56-60%, 61-65%, 66-70%, 71-75%,76-80%, 81-85%, 86-90%, 91-95% or 96-99% of the void-fractioncircumference.

The offset may scale in proportion to the length of the member ormembers. For example, the offset may range from about 1-5%, 6-10%,11-15%, 16-20%, 21-25%, 26-30%, 31-35%, 36-40%, 41-45%, 46-50%, 51-55%,56-60%, 61-65%, 66-70%, 71-75%, 76-80%, 81-85%, 86-90%, 91-95% or 96-99%of the length of the member or members.

The base may be held in place relative to the device by the member ormembers. The base may be held in place relative to the device only bythe member or members.

The methods may include lyophilizing the medicament to produce a vapor.The vapor may escape between the inner wall, the member or members, andthe base. The methods may include lyophilizing the medicament to producean at least partly desiccated form of the medicament.

The methods may include advancing the member or members into the deviceuntil the base seals against the inner wall of the device. The methodsmay include advancing the member or members into the device until thebase seals against the inner wall only after lyophilizing themedicament. The methods may include advancing the member or members intothe device until the flange abuts the terminal surface of the device.The methods may include advancing the member or members into the deviceuntil the flange abuts the terminal surface only after lyophilizing themedicament.

The medicament may include a formulation of one or more compounds. Thecompounds may include naturally occurring substances. The compounds mayinclude substances derived from naturally occurring substances. Thecompounds may include synthetically produced substances. The compoundsmay include chimeric substances. The compounds may include engineeredsubstances. The compounds may include humanized substances. Thecompounds may include substances produced by recombinant techniques. Thecompounds may include substances modified by recombinant techniques.

The compounds may include a drug accepted for therapeutic treatment of apatient. The compounds may include a substance used in a therapeuticprotocol. The compounds may include a substance used in a diagnosticprotocol. The compounds may include a substance used in an experimentalprotocol. The compounds may include a substance compatible for use withapparatus and methods of the invention.

The medicament may include any medical agent listed herein, either aloneor in combination with one or more other listed medical agents or withone or more other, non-listed, medical agents. The medical agents mayinclude anti-glaucoma medications, other ocular agents, neuroprotectiveagents, antimicrobial agents, anti-inflammatory agents (includingsteroids and non-steroidal compounds), and biological agents includinghormones, enzymes or enzyme-related components, antibodies orantibody-related components, oligonucleotides (including DNA, RNA,short-interfering RNA, and other suitable oligonucleotides, such asantisense oligonucleotides), DNA/RNA vectors, viruses or viral vectors,peptides, and proteins. The medical agents may include anti-angiogenesisagents, including angiostatin, anecortave acetate, thrombospondin,vascular endothelial growth factor (VEGF) receptor tyrosine kinaseinhibitors, and anti-VEGF drugs, such as ranibizumab)(LUCENTIS®,bevacizumab (AVASTIN®), pegaptanib (MACUGEN®), sunitinib, and sorafenib,and any of a variety of known small-molecule and transcriptioninhibitors having an anti-angiogenesis effect; ophthalmic drugs,including glaucoma agents, such as adrenergic antagonists, includingbeta-blocker agents such as atenolol, propranolol, metipranolol,betaxolol, carteolol, levobetaxolol, levobunolol and timolol. Themedical agents may include platelet-derived growth factor (PDGF)inhibitors and anti-PDGF drugs. The medical agents may includetransformation growth factor (TGF) inhibitors and anti-TGF drugs. Themedical agents may include anti-inflammatory agents includingglucocorticoids and corticosteroids, such as betamethasone, cortisone,dexamethasone, dexamethasone 21-phosphate, methylprednisolone,prednisolone 21-phosphate, prednisolone acetate, prednisolone,loteprednol, medrysone, fluocinolone acetonide, triamcinolone acetonide,triamcinolone, beclomethasone, budesonide, flunisolide, fluorometholone,fluticasone, hydrocortisone, hydrocortisone acetate and rimexolone; andnon-steroidal anti-inflammatory agents including diclofenac,flurbiprofen, ibuprofen, bromfenac, nepafenac, ketorolac, salicylate,indomethacin, naxopren, naproxen, piroxicam and nabumetone. The medicalagents may include anti-cytokine agents; the medical agents may includeanti-interleukin-6 agents such as tocilizumab (ACTEMRA®)). The medicalagents may include anti-complement agents, including those targetingcomplement factor D (such as an anti-complement factor D antibody or anantigen-binding fragment thereof) such as lampalizumab, and thosetargeting complement factor H (such as an anti-complement factor Hantibody or an antigen-binding fragment thereof). The medical agents mayinclude angiopoietin-specific agents, such as an angiopoietin-2 antibodyor an antigen-binding fragment thereof. The medical agents may includehuman growth hormone. The medical agents may include any suitablemedical agent.

The medicament may include one or more derivatives of any of theabove-mentioned medical agents. The medicament may include advancedforms of any of the above-mentioned medical agents. The medicament mayinclude mutated forms of any of the above-mentioned medical agents. Themedicament may include combinations of any of the above-mentionedmedical agents. The combinations may be incorporated into amulti-specific molecule. The multi-specific molecule may exhibitproperties of its constituent parts. The multi-specific molecule mayexhibit properties different from any if its constituent parts. Themedicament may include depots, hydrogels and pegylated forms of any ofthe above medical agents. The medicament may include any suitable formof any of the above medical agents.

Apparatus and methods in accordance with the invention will now bedescribed in connection with the FIGS. The FIGS. show illustrativefeatures of apparatus and methods in accordance with the principles ofthe invention. The features are illustrated in the context of selectedembodiments. It will be understood that features shown in connectionwith one of the embodiments may be practiced in accordance with theprinciples of the invention along with features shown in connection withanother of the embodiments.

Apparatus and methods of the invention may involve some or all of thefeatures of the illustrative apparatus and/or some or all of the stepsof the illustrative methods. The steps of the methods may be performedin an order other than the order shown and described herein. Someembodiments may omit steps shown and described in connection with theillustrative methods. Some embodiments may include steps that are notshown and described in connection with the illustrative methods.

Illustrative embodiments will now be described with reference to theaccompanying drawings, which form a part hereof.

The apparatus and methods of the invention will be described inconnection with embodiments and features of illustrative devices. Thedevices will be described now with reference to the FIGS. It is to beunderstood that other embodiments may be utilized and structural,functional and procedural modifications may be made without departingfrom the scope and spirit of the present invention.

Some FIGS. may indicate dimensions of apparatus features. Illustrativevalues of the indicated dimensions are presented below followingdescription of all the FIGS.

FIG. 1 shows illustrative medicament delivery device 100. Deliverydevice 100 may include stopper 102. Delivery device 100 may include tube104. Delivery device 100 may include medial plunger 106.

Delivery device 100 is shown in a first operational state.

Stopper 102 may include sealing base 108. Stopper 102 may include one ormore elongated members 110. Elongated members 110 may define, in spacescircumferentially between elongated members 110, one or more voids 112.Stopper 102 may include flange 116.

Tube 104 may be cylindrical. Tube 104 may include distal opening 118.Tube 104 may include inner wall 120. Tube 104 may include terminalsurface 122. Tube 104 may include one or more bypass channels 124.

Medial plunger 106 may sealingly engage inner wall 120. Medial plunger106 may partition tube 104 into medicament chamber 126 and liquidchamber 128. Medicament chamber 126 may be proximally limited by medialplunger 106. Liquid chamber 128 may be distally limited by medialplunger 106. Liquid chamber 128 may be proximally limited by a proximalplunger (not shown).

In the first operational state, stopper 102 may be partially insertedinto tube 104 through distal opening 118. Partial insertion of stopper102 into tube 104 through distal opening 118 may engage elongatedmembers 110 with inner wall 120. Engagement of elongated members 110with inner wall 120 upon the partial insertion of stopper 102 may setsealing base 108 distally apart from distal opening 118. Sealing base108 may be set distally apart from distal opening 118 by offset S.

Void 112 may be distally open to an exterior of tube 104 in a region ofoffset S. Void 112 may be proximally open to medicament chamber 126.Void 112 may provide gas exchange between medicament chamber 126 and theregion of offset S. Gas exchange may be provided through an open-endedconduit (not depicted distinct from its components) that includes: (1)proximally and distally open void 112; (2) circumferentially adjacentelongated members 110 defining void 112 and engaging with inner wall 120alongside void 112; and (3) a region of inner wall 120 circumferentiallyoverlying void 112.

The first operational state may be utilized for lyophilization of amedicament (not shown) that has been placed in medicament chamber 126prior to the partial insertion of stopper 102 into tube 104 throughdistal opening 118. During lyophilization, gas exchanged from medicamentchamber 126 to the exterior of tube 104 via void 112 may be alyophilization byproduct. The lyophilization byproduct may be vaporizedmedicament solvent (not shown). Lyophilization may continue until alyophilized product (not shown) remains in medicament chamber 126. Thelyophilized product may be a caked desiccated medicament.

FIG. 2 shows medicament delivery device 100 in a second operationalstate.

Stopper 102 may be displaced relative to the configuration shown in FIG.1 such that flange 116 abuts terminal surface 122. Flange 116 abuttingterminal surface 122 may seal distal opening 118. Displacing stopper 102such that flange 116 abuts terminal surface 122 may bring sealing base108 into sealing engagement with inner wall 120. Sealing base 108 beingbrought into sealing engagement with inner wall 120 may distally sealmedicament chamber 126.

The second operational state may be utilized for sealing the lyophilizedproduct (not shown) in medicament chamber 126. The second operationalstate may be utilized for storing the lyophilized product in medicamentchamber 126. The lyophilized product in medicament chamber 126 may besealed between stopper 102 and medial plunger 106. Sealing thelyophilized product in medicament chamber 126 between stopper 102 andmedial plunger 106 may contribute to long-term stability of thelyophilized product.

Proximal plunger 230 may sealingly engage inner wall 120. Liquid chamber128 may be proximally limited by proximal plunger 230. Diluent (notshown) may be sealed in liquid chamber 128 between medial plunger 106and proximal plunger 230.

The lyophilized product (not shown) may be reconstituted to a liquidinjectable form of the medicament (not shown). The lyophilized productmay be reconstituted with diluent (not shown) stored in liquid chamber128. The diluent may be transferred from liquid chamber 128 tomedicament chamber 126 through bypass channels 124.

In delivery device 100, transferring diluent to medicament chamber 126through bypass channels 124 may involve advancing proximal plunger 230distally within tube 104 toward medial plunger 106. Transferring diluentto medicament chamber 126 through bypass channels 124 may involveadvancing medial plunger 106 distally within tube 104 toward stopper102. Transferring diluent to medicament chamber 126 through bypasschannels 124 may involve providing a vent (not shown) that passesthrough stopper 102 in the second operational state. A lumen of a needle(not shown) embedded in stopper 102 may provide the vent through stopper102 in the second operational state, the lumen providing fluidcommunication between medicament chamber 126 and the exterior of tube104. The needle may be timely inserted, prior to transferring thediluent, through septum region 611 (shown in FIG. 6 a ) of sealeddelivery device 100. The needle may serve to deliver to a patient (notshown) the liquid injectable form of the medicament reconstituted fromthe lyophilized product.

FIG. 3 shows stopper 102. Stopper 102 may include one or more peripheralsealing ridges 301. Peripheral sealing ridges 301 may be integral tosealing base 108. Peripheral sealing ridges 301 may facilitate sealingengagement of sealing base 108 with inner wall 120 (shown in FIG. 2 ).

Stopper 102 may include sealing ledge 303. Sealing ledge 303 may beintegral to flange 116. Sealing ledge 303 may extend radially inwardfrom a circumferential periphery of flange 116. At an innermost radialextension, sealing ledge 303 may form a circumferential juncture offlange 116 and sealing base 108. Sealing ledge 303 may facilitatesealing of distal opening 118 (shown in FIG. 2 ) when flange 116 abutsterminal surface 122 (shown in FIG. 2 ).

Stopper 102 may include central well 305. Central well 305 may be atleast partly defined by elongated members 110. Elongated members 110 maypartly define central well 305 by merging into webbing surface 307interior to stopper 102. Central well 305 may extend interior to thestopper towards sealing base 108.

FIG. 4 a shows stopper 102, including sealing base 108, elongatedmembers 110, void 112 and flange 116. (FIG. 4 a indicates viewlinesassociated with sealing base 108, elongated members 110, void 112 andflange 116.) Stopper 102 may define longitudinal axis A. Longitudinalaxis A may pass through base 108. Longitudinal axis A may be coaxialwith a central axis of base 108 (not shown).

FIG. 4 b shows stopper 102, in the same view as shown in FIG. 4 a , withassociated illustrative dimensions d1, d2, d3, d4, d5 and d6 indicated.

FIG. 5 shows stopper 102 in a cross-sectional view taken along lines 5-5(through sealing base 108, as shown in FIG. 4 a ). FIG. 5 shows sealingledge 303 surrounding sealing base 108.

FIG. 6 a shows stopper 102 in a cross-sectional view taken along lines6-6 (through flange 116, sealing base 108 and void 112, as shown in FIG.4 a ). FIG. 6 a shows septum surface 609 associated with flange 116.Septum surface 609 may be an outer surface of septum region 611. Septumregion 611 may extend through flange 116 and sealing base 108. Septumregion 611 may extend between septum surface 609 and central well 305.Septum region 611 may be a self-sealing needle-penetrable region,allowing a needle to be inserted, and then extend with its outer wallsealed, from the exterior of medicament delivery device 100 (shown inFIG. 2 ) into central well 305.

Lubricious coating 613 may coat surfaces of stopper 102. Lubriciouscoating 613 may be bonded to coated surfaces. Lubricious coating 613 maycoat surfaces of elongated members 110 and void 112. Lubricious coating613 may coat webbing surface 307. Surfaces of stopper 102 may not bearlubricious coating 613. Surfaces of stopper 102 that serve to sealinglyengage inner wall 120 (shown in FIG. 2 ), such as peripheral sealingridges 301, may not be coated with lubricious coating 613. Surfaces ofperipheral sealing ridges 301 may be selectively coated with lubriciouscoating 613. All or part of the surfaces of none, one or more than oneof peripheral sealing ridges 301 may be coated with lubricious coating613.

FIG. 6 b shows stopper 102, in the same view as shown in FIG. 6 a , withassociated illustrative dimensions d7, d8, d9 and d10 indicated.

FIG. 7 shows stopper 102 in end-view taken along lines 7-7 (alongaspects of elongated members 110 and void 112, as shown in FIG. 4 a ).FIG. 7 shows circumferentially adjacent elongated members 110 definingbetween them void 112. Adjacent surfaces of elongated members 110 thatare on the exterior of stopper 102 may merge to define void 112.Adjacent surfaces of elongated members 110 that are interior to stopper102 may merge to form part of webbing surface 307 of central well 305.

FIG. 8 shows stopper 102 rotated about longitudinal axis A (shown inFIG. 4 a ) relative to the view of stopper 102 shown in FIG. 4 a . Therotation may be a rotation of about 45°. FIG. 8 shows sealing base 108,elongated members 110 and flange 116. (FIG. 8 indicates a viewlinethrough stopper 102, the viewline associated with flange 116, sealingbase 108 and elongated member 110.)

FIG. 9 shows stopper 102 in a cross-sectional view taken along lines 9-9(through flange 116, sealing base 108 and elongated member 110, as shownin FIG. 8 ). FIG. 9 shows sealing base 108, elongated members 110,flange 116 and central well 305.

FIG. 10 a shows tube 104. Tube 104 may include proximal opening 1036.Proximal opening 1036 may be opposite distal opening 118. Proximalopening 1036 may be parallel to distal opening 118. Inner wall 120 mayextend between proximal opening 1036 and distal opening 118. Inner wall120 may extend from proximal opening 1036 to distal opening 118.

FIG. 10 b shows tube 104, in the same view as shown in FIG. 10 a , withassociated illustrative dimensions d11 and d12 indicated.

FIG. 11 shows a cross-sectional view of tube 104. FIG. 11 shows innerwall 120 and bypass channels 124. (FIG. indicates a viewline throughtube 104, the viewline associated with inner wall 120 and bypasschannels 124.)

FIG. 12 shows tube 104 in cross-sectional view taken along lines 12-12(passing through inner wall 120 and bypass channels 124, as shown inFIG. 11 ). FIG. 12 shows tube 104, inner wall 120 and bypass channels124.

FIG. 13 shows medial plunger 106. Medial stopper 106 may include medialplunger face 1325. Medial stopper 106 may include two or more medialplunger side crests 1327. Medial plunger side crests 1327 may be ofdifferent girths parallel to medial plunger face 1325. Differentlygirthed medial plunger side crests 1327 may facilitate sealingengagement of medial plunger 106 with inner wall 120 (shown in FIG. 1 ).Differently girthed medial plunger side crests 1327 may facilitatesliding engagement of medial plunger 106 along inner wall 120 (shown inFIG. 1 ). Medial plunger 106 may include medial plunger side troughs1329.

FIG. 14 a shows a side view of medial plunger 106, including medialplunger face 1325. (FIG. 14 a indicates a viewline through medialplunger 106, the viewline associated with medial plunger face 1325.)

FIG. 14 b shows medial plunger 106, in the same view as shown in FIG. 14a , with associated illustrative dimensions d13 and d14 indicated.

FIG. 15 a shows medial plunger 106 in a cross-sectional view taken alonglines 15-15 (passing through medial plunger face 1325, as shown in FIG.14 a ). FIG. 15 a shows medial plunger side crests 1327 and medialplunger side trough 1329.

FIG. 15 b shows medial plunger 106, in the same view as shown in FIG. 15a , with associated illustrative dimensions d15, d16, d17 and d18indicated.

FIG. 16 shows medial plunger 106 viewed face-on. FIG. 16 shows medialplunger face 1325 and medial plunger side crest 1327. (FIG. 16 indicatesa viewline through medial plunger 106, the viewline associated withmedial plunger face 1325 and medial plunger side crest 1327.)

FIG. 17 shows medial plunger 106 in a face-up cross-sectional view takenalong lines 17-17 (passing through medial plunger face 1325 and medialplunger side crest 1327, as shown in FIG. 16 ). FIG. 17 shows medialplunger face 1325 bearing lubricious coating 1713 a. FIG. 17 shows aface of medial plunger 106 opposite medial plunger face 1325 bearinglubricious coating 1713 b. Lubricious coating 1713 b may include thesame material as lubricious coating 1713 a. Lubricious coating 1713 bmay not include the same material as lubricious coating 1713 a. Thatmaterial may be the same as the material included in lubricious coating613 (shown in FIG. 6 a ).

Lubricious coating 1713 a or lubricious coating 1713 b may coat medialplunger side crests 1327. Lubricious coating 1713 a may selectively coatnone, one or more than one of medial plunger side crests 1327. None, oneor more than one of medial plunger side crests 1327 may not bearlubricious coating 1713 a or lubricious coating 1713 b. Thickness t1 oflubricious coating 1713 a or thickness t2 of lubricious coating 1713 bmay approximate differences of girth among medial plunger side crests1327. Uncoated medial plunger side crests 1327 may be greater in girththan coated medial plunger side crests 1327, the difference approximatedby thickness t1 or thickness t2. Coated medial plunger side crests 1327may facilitate sliding engagement along inner wall 120 (shown in FIG. 2). Uncoated medial plunger side crests 1327 may facilitate sealingengagement with inner wall 120 (shown in FIG. 2 ).

FIG. 18 shows proximal plunger 230. Proximal plunger 230 may includedistal face 1825. Proximal plunger 230 may include proximal plunger sidecrests 1827. Proximal plunger 230 may include proximal plunger sidetrough 1829. Proximal plunger 230 may include leading edge 1831.Proximal plunger 230 may include trailing edge 1833. Proximal stopper200 may include proximal face 1835.

A distal-to-proximal orientation of proximal plunger 230 within tube 104(shown in FIGS. 2 and 10 a) during engagement of proximal plunger 230with inner wall 120 (as shown in FIG. 2 ) may be parallel to adistal-to-proximal alignment of distal opening 118 to proximal opening1036 (both openings shown in FIG. 10 a ). Leading edge 1831 may becloser than trailing edge 1833 to distal opening 118 (shown in FIGS. 2and 10 a). Distal face 1825 may be closer than proximal face 1835 todistal opening 118 (shown in FIGS. 2 and 10 a). Trailing edge 1833 maybe closer than leading edge 1831 to proximal opening 1036 (shown in FIG.10 a ). Proximal face 1835 may be closer than distal face 1825 toproximal opening 1036 (shown in FIG. 10 a ). A distal end of apractitioner-controlled syringe plunger rod (not shown) may act onproximal face 1835 to advance proximal plunger 230 distally within tube104 (shown in FIG. 2 ).

FIG. 19 a shows a side view of proximal plunger 230, including distalface 1825 and proximal face 1835. (FIG. 19 a indicates a viewlinethrough proximal plunger 230, the viewline associated with distal face1825 and proximal face 1835.)

FIG. 19 b shows proximal plunger 230, in the same view as shown in FIG.19 a , with associated illustrative dimension d19 indicated.

FIG. 20 a shows proximal plunger 230 in a cross-sectional view takenalong lines 20-20 (passing through distal face 1825 and proximal face1835, as shown in FIG. 19 a ). FIG. 20 a shows distal face 1825, medialplunger side crests 1827, medial plunger side trough 1829 and proximalface 1835.

FIG. 20 b shows proximal plunger 230, in the same view as shown in FIG.20 a , with associated illustrative dimensions d20, d21, d22, d23 andd24 indicated.

FIG. 21 shows proximal plunger 230 viewed face-on. FIG. 21 shows distalface 1825 and proximal plunger side crest 1827. (FIG. 21 indicates aviewline through proximal plunger 230, the viewline associated withdistal face 1825 and proximal plunger side crest 1827.)

FIG. 22 shows proximal plunger 230 in a face-down cross-sectional viewtaken along lines 22-22 (passing through distal face 1825 and proximalplunger side crest 1827, as shown in FIG. 21 ). FIG. 22 shows medialplunger face 1825 bearing lubricious coating 2213. Medial plunger face1825 may be selectively coated with lubricious coating 2213. None, someor all of a surface of medial plunger face 1825 may be coated withlubricious coating 2213. FIG. 22 shows leading edge 1831 bearinglubricious coating 2213. Leading edge 1831 may be selectively coatedwith lubricious coating 2213. None, some or all of a surface of leadingedge 1831 may be coated with lubricious coating 2213. Lubricious coating2213 may include the same material as lubricious coating 1713 a orlubricious coating 1713 b (both shown in FIG. 17 ).

FIG. 23 shows unvented stopper 2350. Unvented stopper 2350 may have no,one or more than one features in common with stopper 102 (shown in FIG.3 ). Unvented stopper 2350 may include one or more peripheral sealingridges 2351. Peripheral sealing ridges 2351 may be integral to sealingbase 2358. Unvented stopper 2350 may include sealing ledge 2353. Sealingledge 2353 may be integral with flange 2356. Sealing ledge 2353 mayextend radially inward from a circumferential periphery of flange 2356.At an innermost radial extension, sealing ledge 2353 may form acircumferential juncture of flange 2356 and sealing base 2358. Unventedstopper 2350 may include central well 2365 internal to elongated section2370.

FIG. 24 a shows unvented stopper 2350, including flange 2356, sealingbase 2358 and elongated section 2370. (FIG. 24 a indicates viewlinesthrough unvented stopper 2350, the viewlines associated with flange2356, sealing base 2358 and elongated section 2370.)

FIG. 24 b shows unvented stopper 2350, in the same view as shown in FIG.24 a , with associated illustrative dimensions d25, d26, d27, d28 andd29 indicated.

FIG. 25 shows unvented stopper 2350 in a cross-sectional view takenalong lines 25-25 (through sealing base 2358, as shown in FIG. 24 a ).FIG. 25 shows sealing ledge 2353 surrounding sealing base 2358.

FIG. 26 a shows unvented stopper 2350 in a cross-sectional view takenalong lines 26-26 (through flange 2356, sealing base 2358 and elongatedsection 2370, as shown in FIG. 24 a ). FIG. 26 a shows septum surface2369 associated with flange 2356. Septum surface 2369 may be an outersurface of septum region 2371. Septum region 2371 may extend throughflange 2356 and sealing base 2358. Septum region 2371 may extend betweenseptum surface 2369 and central well 2365. Septum region 2371 may be aself-sealing needle-penetrable region.

FIG. 26 b shows unvented stopper 2350, in the same view as shown in FIG.26 a , with associated illustrative dimensions d30, d31 and d32indicated.

FIG. 27 shows unvented stopper 2350 in a cross-sectional view similar tothe view shown in FIG. 26 a . FIG. 27 shows lubricious coating 2713coating surfaces of unvented stopper 2350. Surfaces of unvented stopper2350 may not bear lubricious coating 2713. Lubricious coating 2713 mayselectively coat surfaces of elongated section 2370. None, some or allof a surface of elongated section 2370 may be coated with lubriciouscoating 2713. Lubricious coating 2713 may selectively coat surfaces ofcentral well 2365. None, some or all of a surface of central well 2365may be coated with lubricious coating 2713. Lubricious coating 2713 mayinclude material of lubricious coating 2213 (shown in FIG. 22 ).

FIG. 28 shows illustrative medicament delivery device 2800. Deliverydevice 2800 may include tube 104, including inner wall 120 and bypasschannels 124. Delivery device 2800 may include medial plunger 106sealingly engaging inner wall 120 and partitioning tube 104 intomedicament chamber 126 and liquid chamber 128.

Delivery device 2800 may include unvented stopper 2350. Unvented stopper2350 is shown inserted into tube 104. Unvented stopper 2350 may sealtube 104. Sealing base 2358 of unvented stopper 2350 may sealinglyengage inner wall 120. Sealing ridge 2351 may facilitate sealingengagement of unvented stopper 2350 with inner wall 120. Sealingengagement of unvented stopper 2350 with inner wall 120 and of medialplunger 106 with inner wall 120 may seal a medicament (not shown) withinmedicament chamber 126. The medicament within medicament chamber 126 ofdelivery device 2800 may be in a liquid state.

FIG. 29 shows medicament delivery device 2800 with liquid chamber 128limited on opposing ends by medial plunger 106 and by proximal plunger230, each plunger sealingly engaging inner wall 120. Sealing engagementof medial plunger 106 with inner wall 120 and of proximal plunger 230with inner wall 120 may seal a fluid (not shown) within liquid chamber128. The fluid may be transferred from liquid chamber 128 to medicamentchamber 126 through bypass channels 124.

In delivery device 2800, transferring fluid to medicament chamber 126through bypass channels 124 may involve advancing proximal plunger 230distally within tube 104 toward medial plunger 106. Transferring fluidto medicament chamber 126 through bypass channels 124 may involveadvancing medial plunger 106 distally within tube 104 toward unventedstopper 2350. Transferring fluid to medicament chamber 126 throughbypass channels 124 may involve providing a vent (not shown) that passesthrough unvented stopper 2350. A lumen of a needle (not shown) embeddedin unvented stopper 2350 may provide the vent through unvented stopper2350, the lumen providing fluid communication between medicament chamber126 and an exterior of tube 104. The needle may be timely inserted,prior to transferring the fluid, through septum region 2371 (shown inFIG. 26 a ) of sealed delivery device 2800.

Transferring fluid to medicament chamber 126 through bypass channels 124may facilitate interaction of the fluid with the medicament (not shown)in medicament chamber 126. The interaction may involve mixing. Theinteraction may involve dilution. The interaction may involvereconstitution. The interaction may involve one or more chemicalreactions. The interaction may convert a storage form of the medicament(not shown) stored between medial plunger 106 and unvented stopper 2350into a deliverable form of the medicament. The deliverable form of themedicament may be delivered to a patient (not shown) via the needle (notshown) embedded in unvented stopper 2350.

FIG. 30 a shows tube 3004. Tube 3004 may have no, one or more than onefeatures in common with tube 104 (shown in FIG. 10 a ). Tube 3004 mayinclude distal opening 3018. Tube 3004 may include inner wall 3020. Tube3004 may include proximal opening 3036. Proximal opening 3036 may beopposite distal opening 3018. Proximal opening 3036 may be parallel todistal opening 3018. Inner wall 3020 may extend between proximal opening3036 and distal opening 3018. Inner wall 3020 may extend from proximalopening 3036 to distal opening 3018.

FIG. 30 b shows tube 3004, in the same view as shown in FIG. 30 a , withassociated illustrative dimensions d33 and d34 indicated.

FIG. 31 shows illustrative medicament delivery device 3100. Deliverydevice 3100 may include tube 3004. Delivery device 3100 may includeunvented stopper 2350. Unvented stopper 2350 may seal distal opening3018. Sealing base 2358 may sealingly engage inner wall 3020 proximal todistal opening 3018. Delivery device 3100 may include proximal plunger230. Proximal plunger 230 may sealingly engage inner wall 3020 distal toproximal opening 3036.

Unvented stopper 2350 and proximal plunger 230 may seal a medicament(not shown) within medicament chamber 3026. Medicament chamber 3026 maybe limited proximally by distal face 1825. Medicament chamber 3026 maybe limited distally by proximal features of unvented stopper 2350.

The medicament (not shown) within medicament chamber 3026 may be in aliquid state. The medicament within medicament chamber 3026 may be adeliverable form of the medicament.

A distal end of a practitioner-controlled syringe plunger rod (notshown) may act on proximal face 1835 to advance proximal plunger 230distally within tube 3004. A lumen of a needle (not shown) embedded inunvented stopper 2350 may provide a vent through unvented stopper 2350,the lumen providing fluid communication between medicament chamber 3026and the exterior of tube 3004. The needle may be timely inserted, priorto medicament delivery, through septum region 2371 (shown in FIG. 26 a )of sealed delivery device 3100. The needle may serve to deliver themedicament to a patient (not shown).

Table 1 shows illustrative dimensions, in millimeters, of dimensionsd_(i) shown in, and referenced to, FIGS. 4 b, 6 b, 10 b, 14 b, 15 b, 19b, 20 b, 24 b, 26 b and 30 b .

TABLE 1 Illustrative dimensions of d_(i). d_(i) Value (mm) FIG. in whichd_(i) is shown d1 4.75 FIG. 4b d2 6.40 FIG. 4b d3 2 FIG. 4b d4 1 FIG. 4bd5 1.5 FIG. 4b d6 8.20 FIG. 4b d7 6.60 FIG. 6b d8 2.20 FIG. 6b d9 3 FIG.6b d10 2 FIG. 6b d11 39-54 FIG. 10b d12 6 FIG. 10b d13 4.5 FIG. 14b d146.75 FIG. 14b d15 2.25 FIG. 15b d16 6.30 FIG. 15b d17 6.75 FIG. 15b d186.90 FIG. 15b d19 7.5 FIG. 19b d20 2.50 FIG. 20b d21 0.90 FIG. 20b d226.90 FIG. 20b d23 6.30 FIG. 20b d24 6.75 FIG. 20b d25 6.40 FIG. 24b d262 FIG. 24b d27 1 FIG. 24b d28 1.50 FIG. 24b d29 8.20 FIG. 24b d30 6.60FIG. 26b d31 2.20 FIG. 26b d32 3 FIG. 26b d33 39-54 FIG. 30b d34 6 FIG.30b

Dimensions di are only illustrative. Any suitable dimensions may be usedfor features of medicament delivery device 100 (shown in FIGS. 1 and 2), medicament delivery device 2800 (shown in FIGS. 28 and 29 ) andmedicament delivery device 3100 (shown in FIG. 31 ). Ratios dj:dk andany other suitable ratios of dimensions di may be employed.

Thus, apparatus and methods for sealing a medicament within a medicaldelivery device have been provided. Persons skilled in the art willappreciate that the present invention can be practiced by other than thedescribed embodiments, which are presented for purposes of illustrationrather than of limitation. The present invention is limited only by theclaims that follow.

What is claimed is:
 1. A method of lyophilizing and sealing a medicament within a medical. delivery device, themethod comprising: placing the medicament into the delivery device; engaging an inner wall of the delivery device with a plurality of resilient elongated members that are fixed to a sealing base; advancing the members into the device until the base is set apart from the inner wall by a predetermined offset, the base held in place relative to the device onlyby the members; lyophilizing the medicament to produce avapor that escapes between the inner wall, the members and the base; and, then, further advancing the members until the base seals against the inner wall.
 2. A method of lyophilizing and sealing a medicament within a medical delivery device, themethod comprising: placing the medicament into the device; through an opening of the device, engaging an inner wall of the device with a resilient elongated member that is fixed to a sealing base; advancing the member relative to the opening until the base is set apart from the opening by a predetermined offset, the base held in place relative to the device only by the member; lyophilizing the medicament to produce avapor that escapes between the inner wall, the member and the base; and, then, further advancing the member until the base seals against the inner wall.
 3. The method of claim 1 wherein the members: are set radially away from a central axis of the base; and define, between circumferentially adjacent surfaces of the members, one or more than one void having a circumferential span.
 4. The method of claim 3 wherein the predetermined offset is scaled in proportion to a ratio of the circumferential span to a circumference of the base.
 5. The method of claim 4 wherein the predetermined offset ranges from about 1-35% of the ratio.
 6. The method of claim 4 wherein the predetermined offset ranges from about 31-70% of the ratio.
 7. The method of claim 4 wherein the predetermined offset ranges from about 66-99% of the ratio.
 8. The method of claim 1 wherein the predetermined offkt is scaled in proportion to a length of longitudinal extension of the members from the base.
 9. The method of claim 8 wherein the predetermined offset ranges from about 1-35% of the length.
 10. The method of claim 8 wherein the predetermined offset ranges from about 31-70% of the length.
 11. The method of claim 8 wherein the predetermined offset ranges from about 66-99% of the length.
 12. The method of claim 2 Wherein the member: is set radially away from a central axis of the base; and defines, between circumferentially adjacent surfaces of the member, a void having a circumferential span.
 13. The method of claim 12 wherein the predetermined offset is scaled in proportion to a ratio of the circumferential span to a circumference of the base.
 14. The method of claim 13 wherein the predetermined offset ranges from about 1-35% of the ratio.
 15. The method of claim 13 wherein the predetermined offset ranges from about 31-70% of the ratio.
 16. The method of claim 13 wherein the predetermined offset ranges from about 66-99% of the ratio.
 17. The method of claim 2 wherein the predetermined offset is scaled in proportion to a length of longitudinal extension of the member from the base.
 18. The method of claim 17 wherein the predetermined offset ranges from about 1-35% of the length.
 19. The method of claim 17 wherein the predetermined offset ranges from about 31-70% of the length.
 20. The method of claim 17 wherein the predetermined offset ranges from about 66-99% of the length. 